Led light engine and method of manufacturing

Abstract

The present invention relates to a light emitting diode (LED) light engine. The LED light engine includes at least one LED, the at least one LED having at least one first electrical terminal and at least one second electrical terminal. The LED light engine further includes an electrical cable having a first conductor and a second conductor, the at least one LED being secured to the first conductor by a first insulation displacement connector (IDC) and to the second conductor by a second IDC. The first IDC includes at least one socket for receiving the at least one first electrical terminal and a piercing portion for displacing the insulating portion and electrically contacting the first conductor of the electrical cable. The second IDC includes at least one socket for receiving the second terminal of the at least one LED and a piercing portion for displacing the insulating portion and contacting the second conductor of the electrical cable.

1 - 5 . (canceled) 
   
   
       6 . The LED light engine of  claim 16 , wherein the LED device includes a plurality of electrical terminals, one or more of the plurality of electrical terminals being insulated from the other, for selectively varying an intensity or hue of the at least one LED, the plurality of electrical terminals being in electrical communication with the conductors. 
   
   
       7 . The LED light engine of  claim 16 , wherein the LED light engine is formed into an alphabetic shape. 
   
   
       8 . The LED light engine of  claim 16 , wherein a channel letter housing is disposed about the LED light engine. 
   
   
       9 . The LED light engine of  claim 16 , wherein the overmolded housing substantially encloses the LED device, the first connector, the second connector, and at least a portion of each of the first conductor and the second conductor. 
   
   
       10 . A method of manufacturing an LED light engine, the method comprising:
 inserting a first electrical terminal of an LED into a socket of a first insulation displacement connector (IDC);   inserting a second electrical terminal of the LED into a socket of a second IDC;   inserting the first IDC into an insulated cable proximal to a first conductor of the cable;   inserting the second IDC into the cable proximal to a second conductor of the cable; and   molding a housing over and substantially covering the LED, the first IDC, and the second IDC.   
   
   
       11 . The method of  claim 10 , further comprising the step of orienting the second IDC approximately one hundred and eighty (180) degrees opposite to the orientation of the first IDC prior to inserting the second IDC into the cable, and wherein the first IDC and the second IDC are geometrically identical. 
   
   
       12 . The method of  claim 10 , wherein the step of inserting the first IDC and the step of inserting the second IDC occur simultaneously. 
   
   
       13 . The method of  claim 10 , further comprising the step of inserting the first IDC and the second IDC into a header prior to inserting the terminals of the LED into the respective sockets of the first IDC and the second IDC. 
   
   
       14 . The method of  claim 10 , wherein the molding step further includes molding the housing over a portion of the insulated cable. 
   
   
       15 . The method of  claim 10 , wherein the molding step further comprises injection molding a thermoplastic, liquid injection molding a material, casting a material or extruding a material to form the housing integrally with the LED and the first and second IDCs. 
   
   
       16 . A light emitting diode (LED) light engine, comprising:
 an LED device including a positive terminal and a negative terminal, each depending from the LED;   a first conductor and a second conductor for supplying electrical power to the LED, the first conductor being electrically isolated from the second conductor;   an electrically conductive first connector including a receptacle that receives the positive terminal of the LED and a prong portion that contacts the first conductor of the electrical cable;   an electrically conductive second connector including a receptacle that receives the negative terminal of the LED and a prong portion that contacts the second conductor of the electrical cable; and   an overmolded housing partially encapsulating the LED and at least one of the first connector or the second connector.   
   
   
       17 . The LED light engine of  claim 16 , wherein the receptacle of the first connector and the receptacle of the second connector mechanically receives the respective positive and negative terminals of the LED to restrain the positive and negative terminals in three mutually perpendicular axes. 
   
   
       18 . The LED light engine of  claim 16 , further comprising a header including a first slot and second slot, the first connector and the second connector being slidably engaged with the header. 
   
   
       19 . The LED light engine of  claim 16 , wherein the overmolded housing substantially encloses the LED, the first connector, and the second connector. 
   
   
       20 . The LED light engine of  claim 16 , wherein the overmolded housing comprises a material having a thermal conductivity greater than air. 
   
   
       21 . (canceled) 
   
   
       22 . The LED light engine of  claim 16 , wherein each electrically conductive connector is generally flat. 
   
   
       23 . The LED light engine of  claim 16 , wherein each electrically conductive connector includes two or more receptacles. 
   
   
       24 . The LED light engine of  claim 16 , wherein each receptacle is defined by a raised portion offset from a contact plane, the respective terminals being secured between the raised portion and the contact plane. 
   
   
       25 . A light emitting diode (LED) light engine, comprising:
 an LED including a first terminal and a second terminal, the first terminal and the second terminal each including at least one outwardly protruding tab;   a first conductor and a second conductor for supplying electrical power to the LED, the first conductor being electrically insulated from the second conductor;   a first insulation displacing connector (IDC) including a clip portion for receiving the first terminal of the LED, a prong portion for contacting the first conductor of the electrical cable, and a tab engaging portion for engaging the at least one tab of the first terminal;   a second insulation displacing connector (IDC) including a clip portion for receiving the second terminal of the LED, a prong portion for contacting the second conductor of the electrical cable, and a tab engaging portion for engaging the at least one tab of the second terminal;and   wherein the clip portions and the tab engaging portions of the first and second IDCs cooperate to confine movement of the LED in three mutually perpendicular axes when the first and second terminals of the LED are received into the respective first and second IDC.   
   
   
       26 . The LED light engine of  claim 25 , wherein the tab engaging portion is an aperture. 
   
   
       27 . The LED light engine of  claim 25 , wherein the tab engaging portion is a slot. 
   
   
       28 . The LED light engine of  claim 26 , wherein the slot is tapered. 
   
   
       29 . (canceled) 
   
   
       30 . The LED light engine of  claim 25 , further comprising an overmolded housing substantially enclosing the LED, the first connector, and the second connector.